CHAPTER 4

DESIGN CALCULATION FOR GEARBOX

For design calculation of gear for gear box of Hijet car 20 kW design power at
6500 rpm of engine speed is used. AISI 5160 OQT 400 is chosen for gear material
and all gears are same material. The ultimate tensile strength of the gear material is
2220 MPa. The modulus of elasticity is 207 GPa and the Brinell hardness is 627.

Profile angle selected 20 ° full depth.

4.1. Design Calculation for Gear Box of Hijet Car

Gear design calculation of constant mesh gear, first speed gear, second speed,
third speed gear and reverse gear are as follows:

4.1.1. Design Calculation of Input Speed Gear Mesh

Type of gear = helical gear
∘
Helix angle, ψ = 23
∘
Profile angle, φ = 20
Velocity ratio, V.R = 1.30
Modulus of Elasticity, E = 207 GPa
Brinell hardness = 627
Tensile strength = 2220 MPa
Pinion speed, Np = 6500 rpm
No of teeth for pinion, np = 23
No of teeth for gear, ng = 30
Power = 20kW
Pinion and gear are same material and so pinion is weaker.
So based design on pinion.
Power available is about 97% of the engine power because the frictional
contact between the flywheel and pressure plate.
So design power = 20¿ 0.97 = 19.4 kW
 76

Design procedures are using unknown diameter case.

Lewis’ Equation,
Torsional moment can be calculated by using Equation 3.8.
9550×kW 9550×19 . 4
Mt =
Np = 6500 = 28.50 Nm
np 23
n fp= = =29 . 48
cos 3 ψ cos3 23 , yp = 0.114 (From Appendix A, Table A.1)
The actual induced stress can be calculated by using Equation 3.18.
2M t 2×28 . 50 0 . 40
3 2
= m kπ y p n p cosψ = m ×6×π ×0 .114×23×cos23 = m
3 2 3
Sind
1
V . F=
Let velocity factor, 2
S u 2220
S0 = = =740
Endurance stress, 3 3 MPa

Sall = (S o )×V . F
1
740×106 ×
= 2
= 370 MPa
Sind = Sall
0 . 40
m 3 = 370¿ 106
m = 1.03 mm
Take m = 1 mm (from Standard module series)
D
m = n
Dp = 23 ¿ 1 = 23mm
Dg = 30 ¿ 1 = 30 mm
Pitch line velocity can be calculated by using Equation 3.7.
π ×D p ×N p π ×23×10−3 ×6500
=7 . 83
V =60 =60 m/s
For strength check,
The allowable stress can be calculated by using Equation 3.16.
 77

Sall =
So
( 5.6
5 .6+ √V )
=740×106 ×
5.6
(
5 . 6+ √ 7 .83 )
=493. 46
MPa
0.4
−3 3
=398 . 8
Sind = (1×10 ) MPa
Sall > Sind
Design is satisfied.
Therefore, choose m = 1 mm
S ind 398 .8
k max × 6× =4 . 85
kred = Sall = 493 . 46
bmin = kred ¿ π ¿ m =4.85 ¿ π ¿ 1 =15.23 mm
bmax = k ¿ π ¿ m = 6 ¿ π ¿ 1 = 18.85 mm
Take face width b = 15 mm
For dynamic check,
Transmitted load (Ft) can be calculated by using Equation 3.9.
2M t 2×28 .50
Ft = D p =23×10 = 2478.53 N
−3

The dynamic load (Fd) can be calculated by using Equation 3.21.

21V ( bCcos2 ψ + Ft ) cosψ
Ft+
Fd = 21V + √ bCcos2 ψ + F t

Precision cut error (0.01 mm) at m = 1 mm (From Appendix B, Figure B.2)

C = 114¿ 103 N/m (From Appendix A, Table A.2)
21×7 . 83(15×10−3 ×114×103 ×cos 2 23+2478 . 53)cos23
2478 .53+
Fd = 21×7 . 83+ √ 15×10−3×114×103 ×cos 2 23+2478 .53
= 5095.93 N
The limiting endurance load (F0) can be calculated by using Equation 3.19.

F0 =
S0 by p πmcosψ =740×106 ×15×10−3×0. 114×π ×1×10−3 ×cos23
= 3659.35 N
The limiting wear load (Fw) can be calculated by using Equation 3.20.
D p bKQ
2
Fw = cos ψ
 78

2Dg 2×30
= =1. 13
Q = D g +D p 30+23

Ses = (2.75BHN) – 70 = (2.75 ¿ 627) – 70

= 1654.25 MN/m2

S 2es sin φn 1

K =
1. 4 ( +
1
E p Eg )
∘ ∘ ∘
ϕ = 20 , ψ =23 ,tanϕn = tanϕcosψ, ϕn = 18.52

( 1654 . 25×106 )2 sin18 .52

K = 1. 4 ( 2
207×10 9 )
=6 . 00×10 6
N/m2
23×10−3 ×15×10−3×6 .00×106 ×1 .13
2
Fw = cos 23 = 2765.26 N
Fd > F0 and Fd > Fw
So design is not satisfied.
Therefore, choose m = 2 mm, Face width b = 15 mm
Dp = 23¿ 2 = 46 mm
Dg = 30¿ 2 = 60 mm
V = 15.66 m/s
Ft = 1239.27 N
Fd = 3376.69 N
F0 = 7318.70 N
Fw = 5530.52 N
Fd < F0 and Fd < Fw
So design is satisfied.
D p+ D g
C=
Center distance, 2 = 53 mm
Np
=1 . 3
VR =
N g

Ng = 5000 rpm

4.1.2 Design Calculation of First Speed Gear Mesh

Type of gear = helical gear
 79

∘
Helix angle, ψ = 23
Velocity ratio, VR = 3.1
N
Pinion speed, p = 5000 rpm
No of teeth for pinion, np = 11
No of teeth for gear, ng = 34
Pinion and gear are same material and so pinion is weaker.
So based design on pinion.
Torsional moment can be calculated by using Equation 3.8.
9550×kW 9550×19. 4
= =37 . 05
Mt =
N p 5000 Nm
np11
33
=
=14 . 10
nfp = cos ψ cos 23 , yp = 0.088 (From Appendix A, Table A.1)
The actual induced stress can be calculated by using Equation 3.18.
2M t 2×37 . 05 1 . 40
3 2
= 3 2
= 3
Sind = m kπ y p n p cosψ m ×6×π ×0 . 088×11×cos23 m

1
Let V.F = 2
Sall = S0¿ V.F
1
740×106 ×
= 2
= 370 MPa
Sind = Sall
1. 40
m3 = 370×106
m = 1.56 mm
Take m = 1.5 mm (from Standard module series)
D
m = n
Dp = 11 ¿ 1.5 = 16.5 mm
Dg = 34 ¿ 1.5 = 51 mm
Pitch line velocity can be calculated by using Equation 3.7.
 80

π ×D p ×N p π ×16 .5×10−3 ×5000

= =4 .32
V = 60 60 m/s
For Strength check,
The allowable stress can be calculated by using Equation 3.16.

Sall =
So
( 5.6
5 .6+ √V )
=740×106 ×
5. 6
(
5 . 6+ √ 4 . 32 )
=5 39 . 70
MPa
1 . 40
−3 3
Sind = (1 .5×10 ) = 416.120 MPa
Sall >Sind
Design is satisfied.
Therefore, choose m = 1.5 mm
S ind 416 . 12
k max × 6×
kred = Sall = 539 .70 = 4.63
bmin= kred ¿ π ¿ m =4.6261 ¿ π ¿ 1.5 = 21 mm
bmax= kmax ¿ π ¿ m= 6 ¿ π ¿ 1.5 = 28.27 mm
Take Face width b = 21 mm
For dynamic check,
Transmitted load (Ft) can be calculated by using Equation 3.9.
2M t 2×37 . 05
Ft = D p =16 . 5×10 = 4491.39 N
−3

The dynamic load (Fd) can be calculated by using Equation 3.21.

21V ( bCcos2 ψ + Ft ) cosψ
Ft+
Fd = 21V + √ bCcos2 ψ + F t

Precision cut error (0.01 mm) at m = 1.5 mm (From Appendix B, Figure B.2)
C = 114¿ 103 N/m (From Appendix A, Table A.2)
21×4 . 32(21×10−3 ×114×10 3×cos2 23+4491 .39 )cos 23
4491 . 39+
Fd = 21×4 . 32+ √21×10−3 ×114×103 ×cos 2 23+4491. 39
= 7666.61 N
The limiting endurance load (F0) can be calculated by using Equation 3.19.

F0 =
S0 by p πmcosψ = 740×106 ×21×10−3×0. 088×π ×1 .5×10−3 ×cos23
= 5932.00 N
The limiting wear load (Fw) can be calculated by using Equation 3.20.
 81

D p bKQ
2
Fw = cos ψ
2Dg 2×51
= =1. 51
Q = D g +D p 51+16 . 5
Ses = (2.75BHN) – 70 = (2.75 ¿ 627) – 70
= 1654.25 MN/m2
S 2es sinφn 1

K =
1.4 (+
1
Ep Eg )
∘ ∘ ∘
ϕ = 20 , ψ =23 ,tanϕn = tanϕcosψ, ϕn = 18.52
( 1654 . 25×106 )2 sin18 .52
K = 1. 4 (207×10
2
9)=6 . 00×10 6

N/m2
16 . 5×10−3 ×21×10−3 ×6 . 00×10 6×1 . 51
2
Fw =cos 23 = 3707.38 N
Fd > F0 and Fd > Fw
So design is not satisfied.
Therefore, choose m = 2.5 mm, Face width b = 21 mm
Dp = 11 ¿ 2.5 = 27.5 mm = 28mm
Dp = 34 ¿ 2.5 = 85 mm
V = 7.33 m/s
Ft = 2646.71 N
Fd = 5626.65 N
F0 = 9886.66 N
Fw = 6291.30 N
Fd < F0 and Fd < Fw
So design is satisfied.
Np
=3 . 1
N
VR = g
Ng = 1612.90 rpm

4.1.3 Design Calculation of Second Speed Gear Mesh

Type of gear = helical gear
 82

∘
Helix angle, ψ = 23
Velocity ratio, VR = 1.83
N
Pinion speed, p = 5000 rpm
No of teeth for pinion, np = 18
No of teeth for gear, ng = 33
Pinion and gear are same material and so pinion is weaker.
So based design on pinion.
Torsional moment can be calculated by using Equation 3.8.
9550×kW 9550×19. 4
= =37 . 05
Mt =
N p 5000 Nm
np18
33
==23 . 08
nfp = cos ψ cos 23 , yp = 0.106 (From Appendix A, Table A.1)
The actual induced stress can be calculated by using Equation 3.18.
2M t 2×37 . 05 0 .71
3 2
Sind = m kπ y p n p cosψ = m ×6×π ×0 .106×18×cos23 = m
3 2 3

1
Let V.F = 2
Sall = S0¿ V.F
1
= 740¿ 106¿ 2
= 370 MPa
Sind = Sall
0 .71
m3 = 370 ¿ 106
m = 1.24 mm
Take m = 1.25 mm (from Standard module series)
D
m = n
Dp = 18 ¿ 1.25 = 22.5 mm
Dg = 33 ¿ 1.25 = 41.25 mm
Pitch line velocity can be calculated by using Equation 3.7.
π ×D p ×N p π ×22 .5×10−3 ×5000
V =60 =60 = 5.89 m/s
 83

For strength check,

The allowable stress can be calculated by using Equation 3.16.

Sall =
S0
( 5. 6+5 .6√V ) =
740×106 ×
( 5 . 6+5√. 65. 89 )
= 516.26 MPa
0 . 7125
−3 3
Sind = (1 .25×10 ) = 364.80 MPa
Sall = Sind
Design is satisfied.
Therefore, choose m = 1.25 mm
S ind 364 . 80
k max × 6×
kred = Sall = 516 .26 = 4.24
bmin= kred ¿ π ¿ m = 4.24 ¿ π ¿ 1.25 = 16 mm
bmax= kmax ¿ π ¿ m = 6 ¿ π ¿ 1.25 = 23.56 mm
Take Face width b = 16 mm
For dynamic check,
Transmitted load (Ft) can be calculated by using Equation 3.9.
2M t 2×37 .05
Ft = D p = 22 .5×10
−3
= 3293.69 N
The dynamic load (Fd) can be calculated by using Equation 3.21.
21V ( bCcos2 ψ + Ft ) cosψ
Ft+
Fd = 21V + √ bCcos2 ψ + F t

Precision cut error (0.01 mm) at m = 1.25 mm (From Appendix B, Figure B.2)
C = 114¿ 103 N/m (From Appendix A, Table A.2)
21×5 . 89(16×10−3 ×114×103 ×cos 2 23+3293 . 69)cos23
3293 . 69+
Fd = 21×5 . 89+ √ 16×10−3×114×103 ×cos 2 23+3293 .69
= 6144.82 N
The limiting endurance load (F0) can be calculated by using Equation 3.19.
F0 = S0bypπmcosψ = 740¿ 106¿ 16¿ 10-3¿ 0.106¿ π¿ 1.25¿ 10-3¿ cos23
= 4536.74 N
The limiting wear load (Fw) can be calculated by using Equation 3.20.
D p bKQ
2
Fw = cos ψ
 84

2Dg 2×41. 25
= =1 . 29
Q = D g +D p 41 .25+22. 5
Ses = (2.75BHN) – 70 = (2.75 ¿ 627) – 70 = 1654.25 MN/m2
S 2es sinφn 1

K =
1.4 ( +
1
Ep Eg )
∘ ∘ ∘
ϕ = 20 , ψ =23 ,tanϕn = tanϕcosψ, ϕn = 18.52
( 1654 . 25×106 )2 sin18 .52
K = 1. 4 (207×10
2
)=6 . 00×10
9
6

N/m2
22 .5×10−3 ×16×10−3 ×6 . 00×10 6×1 . 29
2
Fw =cos 23 = 3298.68N
Fd > F0 and Fd > Fw. So design is not satisfied.
Therefore, choose m = 2 mm, Face width b = 16 mm
D p =18×2=36 mm

D g =33×2=66 mm
V = 9.4247 m/s
For dynamic check,
Ft = 2058.56 N
Fd = 4604.02 N
F0 = 7258.78 N
Fw = 5301.95 N
Fd < F0 and Fd < Fw
So design is satisfied.
Np
=1 . 8
VR = N g

Ng = 2777.78 rpm

4.1.4. Design Calculation of Third Speed Gear Mesh

Type of gear = helical gear
∘
Helix angle, ψ = 23
Velocity ratio, VR = 1.16
N
Pinion speed, p = 5000 rpm
 85

No of teeth for pinion, np = 25

No of teeth for gear, ng = 29
Pinion and gear are same material and so pinion is weaker.
So based design on pinion.
Torsional moment can be calculated by using Equation 3.8.
9550×kW 9550×19. 4
= =37 . 05
Mt =
N p 5000 Nm
np
25
33
=
=32 .05
nfp= cos ψ cos 23 , yp = 0.116 (From Appendix A, Table A.1)
The actual induced stress can be calculated by using Equation 3.18.
2M t 2×37 . 05 0. 47
3 2
= 3 2
= 3
Sind = m kπ y p n p cosψ m ×6×π ×0 . 116×25×cos23 m

1
Let V.F= 2
Sall = S0¿ V.F
1
= 740¿ 106¿ 2
= 370 MPa
Sind = Sall
0 . 47
m3 = 370 ¿ 106
m = 1.08 mm
Take m = 1 mm (from Standard module series)
D
m = n
Dp = 25 ¿ 1 = 25 mm
Dg = 29 ¿ 1 = 29 mm
π×D p ¿ N p π ×25×10−3 ×5000
V = 60 = 60 = 6.55 m/s
For strength check,
The allowable stress can be calculated by using Equation 3.16.

Sall =
S0
( 5 .6
5. 6+ √V =)740×106 ×
(5.6
)
5 . 6+ √ 6 .55 = 507.95 MPa
 86

0 . 47
−3 3
Sind = (1×10 ) = 468.80 MPa
Sall > Sind
Design is satisfied.
Therefore, choose m = 1 mm
S ind 468 . 80
k max × 6×
kred = Sall = 507 . 95
= 5.54
bmin= kred ¿ π ¿ m = 5.54 ¿ π ¿ 1 = 17.40 mm
bmax= kmax ¿ π ¿ m = 6 ¿ π ¿ 1 = 18.85 mm
Take Face width b = 17 mm
For dynamic check,
Transmitted load (Ft) can be calculated by using Equation 3.9.
2M t 2×37 . 05
Ft = D p = 25×10 = 2964.32 N
−3

The dynamic load (Fd) can be calculated by using Equation 3.21.

21V ( bCcos2 ψ + Ft ) cosψ
Ft+
Fd = 21V + √ bCcos2 ψ + F t

Precision cut error (0.01 mm) at m = 1.25 mm (From Appendix B, Figure B.2)
C = 114¿ 103 N/m (From Appendix A, Table A.2)
21×6 . 55(17×10−3 ×114×103 ×cos 2 23+2964 .32 )cos 23
2964 . 32+
Fd = 21×6 . 55+ √ 17×10−3 ×114×103 ×cos 2 23+2964 . 32
= 5802.87 N
The limiting endurance load (F0) can be calculated by using Equation 3.19.
F0 = S0bypπmcosψ = 740¿ 106¿ 17¿ 10-3¿ 0.116¿ π¿ 1¿ 10-3¿ cos23
= 4220.02 N
The limiting wear load (Fw) can be calculated by using Equation 3.20.
D p bKQ
2
Fw = cos ψ
2D g 2×29
= =1. 07
Q = Dg +D p 29+25
Ses = (2.75BHN) – 70 = (2.75 ¿ 627) – 70 = 1654.25 MN/m2
 87

S 2es sinφn 1

K =
1.4 ( +
1
Ep Eg )
∘ ∘ ∘
ϕ = 20 , ψ =23 ,tanϕn = tanϕcosψ, ϕn = 18.52

( 1654 . 25×106 )2 sin18 .52

K = 1. 4 (207×10
2
)=6 . 00×10
9
6

N/m2
25×10−3 ×17×10−3 ×6 .00×106 ×1 . 07
2
Fw = cos 23
= 3231.94 N
Fd > F0 and Fd > Fw
So design is not satisfied.
Therefore, choose m = 2 mm, Face width b = 17 mm
Dp = 25¿ 2 = 50 mm
Dg = 29¿ 2 = 58 mm
V = 13.09 m/s
For dynamic check,
Ft = 1482.16 N
Fd = 3872.11 N
F0 = 8440.04 N
Fw = 6463.88 N
Fd < F0 and Fd < Fw
So design is satisfied.
Np
=1 . 16
N
VR = g
Ng = 4310.34 rpm

4.1.5. Design Calculation of Reverse Speed Gear Mesh (Pinion to Idler Gear)
Type of gear = helical gear
∘
Helix angle, ψ = 23
Velocity ratio, VR = 1.375
N
Pinion speed, p = 5000 rpm
No of teeth for pinion, np = 16
 88

No of teeth for gear, ng = 22

Pinion and gear are same material and so pinion is weaker.
So based design on pinion.
Torsional moment can be calculated by using Equation 3.8.
9550×kW 9550×19. 4
= =37 . 05
Mt =
N p 5000 Nm
np16
33
=
=20 . 51
nfp = cos ψ cos 23 , yp = 0.104 (From Appendix A, Table A.1)
The actual induced stress can be calculated by using Equation 3.18.
2M t 2×37. 05 0. 82
3 2
= 3 2
= 3
Sind = m kπ y p n p cosψ m ×6×π ×0 . 104×16×cos23 m

1
Let V.F = 2
Sall = S0¿ V.F
1
= 740¿ 10 6¿ 2
= 370 MPa
Sind = Sall
0 .82
m3 = 370 ¿ 106
m = 1.30 mm
Take m = 1.25 mm (from Standard module series)
D
m = n
Dp = 16 ¿ 1.25 = 20 mm
Dg = 22 ¿ 1.25 = 27.5 mm
Pitch line velocity can be calculated by using Equation 3.7.
π ×D p ×N p π ×20×10−3 ×5000
V = 60 = 60 = 5.24 m/s
For strength check,
The allowable stress can be calculated by using Equation 3.16.
 89

Sall =
So
( 5.6
5 .6+ √V )
=740×106 ×
(
5.6
5 . 6+ √ 5. 24 )
=525 . 34
MPa
0 . 82
−3 3
Sind = (1 .25×10 ) = 418.30 MPa
Sall > Sind
Design is satisfied.
Therefore, choose m = 1.25 mm
S ind 418 . 30
k max × 6×
kred = Sall = 525 .34 = 4.78
bmin= kred ¿ π ¿ m = 4.78 ¿ π ¿ 1.25 = 18.76 mm
bmax= kmax ¿ π ¿ m = 6 ¿ π ¿ 1.25 = 23.56 mm
Take Face width b = 19 mm
For dynamic check,
Transmitted load (Ft) can be calculated by using Equation 3.9.
2M t 2×37 . 05
Ft = D p = 20×10 = 3705.40 N
−3

The dynamic load (Fd) can be calculated by using Equation 3.21.

21V ( bCcos2 ψ + Ft ) cosψ
Ft+
Fd = 21V + √ bCcos2 ψ + F t

Precision cut error (0.01 mm) at m = 1.25 mm (From Appendix B, Figure B.2)
C = 114¿ 103 N/m (From Appendix A, Table A.2)
21×5 . 24 (19×10−3 ×114×103 ×cos2 23+3705. 40 )cos23
3705 . 40+
Fd = 21×5 . 24+ √19×10−3 ×114×10 3×cos2 23+3705 . 40
= 6746.74 N
The limiting endurance load (F0) can be calculated by using Equation 3.19.
F0 = S0bypπmcosψ = 740¿ 106¿ 19¿ 10-3¿ 0.104¿ π¿ 1.25¿ 10-3¿ cos23
= 5285.73 N
The limiting wear load (Fw) can be calculated by using Equation 3.20.
D p bKQ
2
Fw = cos ψ
2D g 2×27 .5
= =1 .2
D
Q = g +D p 27 .5+20
 90

Ses = (2.75BHN) – 70 = (2.75 ¿ 627) – 70 = 1654.25 MN/m2

S 2es sinφn 1

K =
1.4 ( +
1
Ep Eg )
∘ ∘ ∘
ϕ = 20 , ψ =23 ,tanϕn = tanϕcosψ, ϕn = 18.52

( 1654 . 25×106 )2 sin18 .52

K = 1. 4 (207×10
2
)=6 . 00×10
9
6

N/m2
20×10-3×19×10−3 ×6 . 00×10 6 ×1. 2
2
=3228. 75
Fw =cos 23 N
Fd > F0 and Fd > Fw
So design is not satisfied.
Therefore, choose m = 2 mm, Face width b = 19 mm
Dp = 16¿ 2= 32 mm
Dg = 22¿ 2 = 44 mm
V = 8.38 m/s
For dynamic check,
Ft = 2315.88 N
Fd = 5112.75 N
F0 = 8457.16 N
Fw = 5166.01 N
Fd < F0 and Fd < Fw
So design is satisfied.
Np
=1 . 38
N
VR = g
Ng = 3636.36 rpm
4.1.6. Design Calculation of Reverse Speed Gear Mesh (Idler to Gear)
Type of gear = helical gear
∘
Helix angle, ψ = 23
Velocity ratio, VR = 1.45
Pinion speed, Np = 3636.36 rpm
No of teeth for pinion, np = 22
No of teeth for gear, ng = 32
Pinion and gear are same material and so pinion is weaker.
 91

So based design on pinion.

Torsional moment can be calculated by using Equation 3.8.
9550×kW 9550×19. 4
= =50 . 95
Mt =
N p 3636 .36 Nm
np
22
3
3
=
=28 . 21
nfp =cos ψ cos 23 , yp = 0.112 (From Appendix A, Table A.1)
The actual induced stress can be calculated by using Equation 3.18.
2M t 2×50 .95 0 .76
3 2
= 3 2
= 3
Sind = m kπ y p n p cosψ m ×6×π ×0 . 112×22×cos23 m

1
Let V.F = 2
Sall = S0¿ V.F
1
= 740¿ 106¿ 2
= 370 MPa
Sind = Sall
0 .76
m3 = 370 ¿ 106
m = 1.27 mm
Take m = 1.25 mm (from Standard module series)
D
m = n
Dp = 22 ¿ 1.25 = 27.5 mm
Dg = 32 ¿ 1.25 = 40 mm
Pitch line velocity can be calculated by using Equation 3.7.
π ×D p ×N p π ×27 .5×10−3 ×3636 . 36
V = 60 = 60 = 5.24 m/s
For strength check,
The allowable stress can be calculated by using Equation 3.16.

Sall =
S0
( 5 .6
5. 6+ √V )
=740×10 6 ×
(5.6
5 .6+ √5 . 24 )
=525 .34
MPa
0 . 76
−3 3
Sind = (1 .25×10 ) = 388.40 MPa
 92

Sall > Sind

Design is satisfied.
Therefore, choose m = 1.25 mm
S ind 388 . 40
k max × 6×
kred= Sall = 525 .34 = 4.44
bmin= kred ¿ π ¿ m = 4.44 ¿ π ¿ 1.25 = 17.42 mm
bmax= kmax ¿ π ¿ m = 6 ¿ π ¿ 1.25 = 23.56 mm
Take Face width b = 17 mm
For dynamic check,
Transmitted load (Ft) can be calculated by using Equation 3.9.
2M t 2×50 . 95
= −3
Ft = D p 27 . 5×10
= 3705.40 N
The dynamic load (Fd) can be calculated by using Equation 3.21.
21V ( bCcos2 ψ + Ft ) cosψ
Ft+
Fd = 21V + √ bCcos2 ψ + F t

Precision cut error (0.01 mm) at m = 1.25 mm (From Appendix B, Figure B.2)
C = 114¿ 103 N/m (From Appendix A, Table A.2)
21×5 . 24 (17×10−3×114×103 ×cos 2 23+3705 . 40)cos23
3705 . 40+
Fd = 21×5 . 24+ √17×10−3 ×114×10 3×cos2 23+3705. 40
= 6661.69 N
The limiting endurance load (F0) can be calculated by using Equation 3.19.
F0 = S0bypπmcosψ =740¿ 106¿ 17¿ 10-3¿ 0.112¿ π¿ 1.25¿ 10-3¿ cos23
= 5093.13 N
The limiting wear load (Fw) can be calculated by using Equation 3.20.
D p bKQ
2
Fw = cos ψ
2Dg 2×40
= =1. 19
Q = D g +D p 40+27 . 5
Ses = (2.75BHN) – 70 = (2.75 ¿ 627) – 70 = 1654.25 MN/m2
S 2es sinφn 1

K =
1.4
+
1
Ep Eg ( )
 93

∘ ∘ ∘
ϕ = 20 , ψ =23 ,tanϕn = tanϕcosψ, ϕn = 18.52
( 1654 . 25×106 )2 sin18 .52
K = 1. 4 (207×10
2
)=6 . 00×10
9
6

N/m2
27 . 5×10 -3×17×10−3 ×6 . 00×106 ×1 . 19
2
=3923 . 23
Fw = cos 23 N
Fd > F0 and Fd > Fw
So design is not satisfied.
Therefore, choose m = 2 mm, Face width b = 17 mm
Dp = 22 ¿ 2 = 44 mm
Dg = 32 ¿ 2 = 64 mm
V = 8.38 m/s
For dynamic check,
Ft = 2315.87 N
Fd = 4999.54 N
F0 = 8149.01 N
Fw = 6277.16 N
Fd < F0 and Fd < Fw
So, design is satisfied.
Np
=1 . 46
VR =
N g

Ng = 2500.08 rpm

4.2. Design Calculation of Shafts

In design calculation of the counter shaft, main shaft and idler shaft, it is
necessary to consider all the effect of bending, torsion and axial load effect since the
shafts are for the automobile transmission use. Shafts are made up of AISI 1020
Annealed. The diameter of the main shaft and counter shaft can be determined by
ASME code equation for first, second, third, fifth speed ranges. Bending moment and
loading diagram of counter shaft (first position) are as shown in Figure. 4.1.
4.2.1. Design Calculation of Counter Shaft at 1st position
Design power = 19.4 kW
Shaft speed = 5000 rpm
DB = 60 mm
 94

DE = 28 mm
WC = 3.88 N
WD = 1.31 N
WG = 1.18 N
Torsional moment of shaft (Mt) can be calculated by using Equation 3.8.
9550×kW 9550×19. 4
M t= = =37. 05
rpm 5000 Nm
For gear (4),
Tangential force can be calculated by using Equation 3.9.
2Mt 2×37 .05
F tB= = = 1235 . 13
DB 0 . 06 N
The radial force can be calculated by using Equation 3.11.
F rB=F tB tan φ=1235 .13×tan20= 449 . 55 N

The axial force can be calculated by using Equation 3.10.

F aB=F tB tanψ=1235 .13×tan23=524 .28 N

For gear (1),

Tangential force can be calculated by using Equation 3.9.
2M t 2×37 . 05
F tE= = =2646 .71
DE 0 . 028 N
The radial force can be calculated by using Equation 3.11.
F rE=F tE tanφ=2646. 71×tan20=963 . 33 N

The axial force can be calculated by using Equation 3.10.

F aE=F tE tanψ=2646 .71×tan23=1123 . 46 N

Taking moment about A, ∑ M A =0 (clockwise positive)

0=( F aB×0 . 023 ) + ( F aE ×0 . 155 )−( RFx ×0 . 173 )

0=( 524 . 28×0 . 023 ) + ( 1123 . 46×0 . 155 )−0 . 173R Fx

RFx =1076 . 27 N

B C
D E G
A F H

0.023m 0.056m 0.018m 0.058m 0.018m 0.02m 0.02m

 95

805.97 N

Figure 4.1. Bending Moment Diagram of Counter Shaft at First Speed Position
 96

∑ F y +↑=0
RAx = FaB + FaE− RFx
RAx = 524.28+1123.46− 1076.27 = 571.47 N
From Vertical Load Diagram (V.L.D) (For Figure 4.1),

Taking moment about A, ∑ M A + = 0 (clockwise positive)

−( F rB×0 . 023 ) + ( W C ×0. 079 ) + ( W D×0. 097 ) + ( F rE×0. 155 ) −( R Fy ×0 .173 )
+ ( W G×0 . 193 )=0

−( 449.55×0. 023 )+ (3 . 88×0 .079 )+ ( 1. 30×0 .097 )+ ( 963. 33×0 .155 )−0 .173R Fy
+ ( 1 .18×0 .193 )=0
RFy =807 .15 N

∑ F y +↑=0
R Ay =F rB−W C −W D−F rE +R Fy −W G
R Ay =449 .55−3 . 88−1 .31−963 .32+807 .15−1. 18=287 . 01 N
Calculation of horizontal shearing force and bending moment.
Span AB (0 < x < 0.023m)
X
A B

RAx x
X

Fxx = RAx = 571.47 N

x = 0 → FA = 571.47 N
x = 0.023m → FB= 571.47 N
Mxx = RAx ¿ x
x = 0 → MA = 0 Nm
x = 0.023m → MB=571.47¿ 0.023=13.14 Nm
Span BE (0.023m < x < 0.155m)
 97

FaB X
0.023
B E
A
RAx x
X
Fxx = RAx− FaB = 571.47− 524.28 = 47.19 N
x = 0.023 m → FB = 47.19 N
x = 0.155 m → FE= 47.19 N
M xx =( R Ax× x ) −F aB ( x−0 .023 )= (571 . 47×x )−524 . 2829( x−0 . 023)

x = 0.023m → MB = 13.14 Nm
x = 0.155m → ME=19.37 Nm

Span EF (0.155m < x < 0.173m)

FaB FaE X
0.023m 0.132m
A
RAx B E F
x

X
F xx=R Ax −F aB−F aE=571 . 47−524 . 28 −1123. 46=−1076 . 27 N
x = 0.155 m → FE = − 1076.27 N
x = 0.173 m → FF= − 1076.27 N
Mxx = (RAx ¿ x) − FaB(x− 0.023) − FaE(x− 0.155)
= (571.47¿ x) − 524.28(x− 0.023) − 1123.46(x− 0.155)
x = 0.155 m → ME = 19.37 Nm
x = 0.173 m → MF= 0 Nm

Span FE (0.04m < x < 0.058m)

X
F 0.04m
E G

X RFx

Fxx = RFx = 1076.27 N

 98

x = 0.04 m → FF = 1076.27 N
x = 0.058 m → FE= 1076.27 N
Mxx = RFx (x− 0.04)
x = 0.04 m → MF = 0 Nm
x = 0.058 m → ME= 19.37 Nm
Calculation of vertical shearing force and bending moment.
Span AB (0 < x < 0.023m)

RAx X

A B

x X
F yy =−RAy =−287 . 01 N
x = 0 → FA = − 287.01 N
x = 0.023m → FB=− 287.01 N
M yy =−R Ay×x
x = 0 → MA = 0 Nm
x = 0.023m → MB=− 287.01¿ 0.023=− 6.60Nm
Span BC (0.023 < x < 0.079m)

RAy X
x
A
B C
0.023m
FrB X

Fyy = − RAy + FrB = − 287.01 + 449.55 =162.54 N

x = 0.023 m → FB = 162.54 N
x = 0.079m → FC =162.54 N
Myy = − RAy ¿ x + FrB¿ (x − 0.023)
= − 287.01x + 449.55(x− 0.023)
x = 0.023 m → MB =− 6.60 Nm
x = 0.079 m → MC= 2.50 Nm
Span CD (0.079m < x <0.097m)
 99

RAy WC X
0.023mm 0.056mm
A B D
C
FrB
x
X
F yy =−RAy +F rB−W C =−287 . 01+449. 55−3. 88=158 .66 N
x = 0.079 m → FC = 158.66 N
x = 0.097m → FD=158.66 N
M yy =−R Ay×x+F rB×( x−0 .023 )−W C (x−0 .079 )
= − 287.01x+449.55(x− 0.023) − 3.88(x− 0.079)
x = 0.079 m → MC =2.50 Nm
x = 0.097 m → MD= 5.36 Nm

Span GF (0.02m < x < 0.04m)

WG
X 0.02mm
F
H
G
X x

F yy =W G=1 . 18 N
x = 0.02 m → FG = 1.18 N
x = 0.097m → FF=1.18 N
M yy =−W G ( x−0 . 02 )=−1 .18 ( x−0 . 02)
x = 0.02 m → MG = 0 Nm
x = 0.04 m → MF= − 0.02 Nm

Span FE (0.04m < x <0.058m)

 100

X WG
0.02mm 0.02mm
F
E H
RFy G
x
X

F yy =W G−R Fy =1 .18−807 .15=−805 . 97 N

x = 0.04 m → FF = − 805.97 N
x = 0.058m → FE= − 805.97 N
M yy =−W G ( x−0 . 02 ) +RFy ( x−0 . 04 )=−1 .18 ( x−0 . 02)+807 . 15( x−0 . 04 )
x = 0.04 m → MF = − 0.02 Nm
x = 0.058 m → ME= 14.46 Nm
Span ED (0.058m < x <0.116m)
WG
FrE
X 0.058m 0.02mm 0.02mm
m
D H
E F G
RFy
x
X

F yy =W G−R Fy +F rE =1. 18−807 .15+963 .33 = 157.36 N

x = 0.058 m → FE = 157.36 N
x = 0.116 m → FD= 157.36 N
M yy =−W G ( x−0 . 02 ) +RFy ( x−0 . 04 )−963 . 33( x−0 . 058 )
= − 1.18(x− 0.02)+807.15(x− 0.04) − 963.33(x− 0.058)
x = 0.058 m → ME = 14.46 Nm
x = 0.116 m → MD= 5.36 Nm
Resultant moment,

M rE =√ M 2EH +M 2EV =√ ( 19 .37 ) + ( 14 . 46 ) =24 .18 Nm

2 2

Therefore maximum bending moment is 24.18 Nm.

Maximum bending moment occurs at gear with key way.
So, Ss = 0.75¿ 0.3¿ 290 = 65.25 MPa
 101

Ss = 0.75¿ 0.18¿ 414 = 55.89 MPa

Choose, Ss = 55.89MPa
For rotating shaft with load gradually applied.
Kb = 1.5, Kt = 1, L =213 mm
Radius of gyration can be calculated by using Equation 3.90.
d
k=
4
Column-action factor can be calculated by using Equation 3.88.
1 1
α= =
1−0 . 0044 ()L
k
1−0 . 0044 ( 0. 213×4
d )
d
=
d−0. 0041
Solid shaft having axial loading can be calculated by using Equation 3.86.

√( ) +( K M )
2
16 αF d
d = 3
K b M b+ a t t
2
πSs 8

√( )
2
d
×1123.46×d
16 d−0.0041 2
d 3= 1 .5×24 .18+ + (1×37.05 )
π×55.8×106 8
d = 0.017 m
d = 17.1 mm
Standard size of shaft is 18 mm
So diameter of the counter shaft at 1st position is 18 mm.
The diameter of counter shaft is based on 1st position which has maximum torque.
Therefore the optimum diameter is chosen 18 mm to satisfy the various speeds.

4.2.2. Design Calculation of Main Shaft at 1st Position

Design power = 19.4 kW
Shaft speed = 1612.90 rpm
DD = 85 mm
WB = 3.88 N
WC = 4.78 N
 102

WF = 5.33 N
The torsional moment of shaft (Mt) can be calculated by using Equation 3.8.
9550×kW 9550×19. 4
M t= = =114 . 87
rpm 1612. 9032 Nm
For gear (1),
Tangential force can be calculated by using Equation 3.9.
2M t 2×114 .87
FtD = D D = 0 . 085 = 2702.76 N
Radial force can be calculated by using Equation 3.11.
F rD =F tD tan φ=2702 . 76×tan20=983 . 73 N
Axial force can be calculated by using Equation 3.10.
F aD =F tD tanψ=27 02 . 76×tan23=1147. 26 N
From Horizontal Load Diagram (H.L.D) (From Figure 4.2),

Taking moment about A, ∑ M A += 0 (clockwise positive)

( R Ex×0. 164 )−( F aD×0 . 146 ) =0
0.164 REx − (1147.26 − 0.146) =0
REx = 1021.34 N

∑ F y +↑=0
R Ax=F aD −R Ex
R Ax=1147 .26−1021 .34=125 . 92 N
From Vertical Load Diagram (V.L.D) (From Figure 4.2),

Taking moment about A, ∑ M A += 0 (clockwise positive)

( W B×0. 07 ) +( W C ×0 .088 )−( F rD ×0 . 146 ) +0 . 164R Ey + ( W b ×0 .184 )=0
( 3 . 88×0 . 07 ) + ( 4 . 78×0 . 088 )− ( 983. 73×0 .146 )−0 .164R dy + ( 5 . 33×0 . 184 )=0
REy =865 . 55 N

∑ F y +↑=0
−R Ay −W 3 −W 2 +F rD−R Ey−W b =0
R Ay=−3. 8823−4 . 7819+983 . 7251−865 . 552−5 . 3274=104 .1782 N
Calculation of horizontal shearing force and bending moment.
 103

Span AD (0 < x < 0.146m)

A D

RAx x
X

Fxx = RAx = 125.92 N

x = 0 → FA = 125.92 N
x = 0.023m → FD=125.92 N
Mxx = RAx ¿ x = 125.92 ¿ x
x = 0 → MA = 0 Nm
x = 0.146m → MD=18.38 Nm
D
C
B
F
A E G

0.07m 0.018m 0.058m 0.018m0.02m 0.02m

FaD
H.L.D
RAx REx
125.92N

H.S.F.D

1021.34N
18.38Nm

H.B.L.D
WC
RAy WB REy WF
V.L.D
FrD

870.88N
5.33N
V.S.F.D
104.18N
108.06N
112.84N
 104

Figure 4.2. Loading and Bending Moment Diagram of Main Shaft at First Speed
Position
 105

Bending moment and loading diagram of main shaft (first position) are as
shown in Figure. 4.2.
Span DE (0.146m < x < 0.164m)
0.146m FAD X
A E
D
RAx x
X

Fxx = RAx − FaD = 125.92 − 1147.26 = − 1021.34 N

x = 0.146 m → FD = − 1021.34 N
x = 0.164 m → FE= − 1021.34 N
Mxx = (RAx ¿ x) − FaD(x − 0.146) = (125.92 ¿ x) − 1147.26(x − 0.146)
x = 0.146 m → MD = 18.38 Nm
x = 0.146m → MD= 0 Nm
Span ED (0.04m < x < 0.058m)
X
D E
REx F
0.04m
X x

Fxx = − REx = − 1021.34 N

x = 0.04 m → FE = − 1021.34 N
x = 0.058 m → FD= − 1021.34 N
Mxx = REx (x − 0.04) = 1021.34(x − 0.04)
x = 0.04 m → ME = 0 Nm
x = 0.058 m → MD= 18.38 Nm
Calculation of vertical shearing force and bending moment.
Span AB (0 < x < 0.07 m)

RAy X
B
A

x X
F yy =−RAy =−104 . 18 N
x = 0 → FA = − 104.18N
x = 0.07 m → FB= − 104.18N
M xx =−R Ay x=−104 . 18x
x = 0 → MA = 0 Nm
x = 0.07 m → MB= − 7.29 Nm
 106

Span BC (0.07 < x < 0.088 m)

RAy 0.07m WB X
A C
Bx

X
Fyy = − RAy − WB = − 104.18 − 3.88 = − 108.06 N
x = 0.07 m → FB = − 108.06 N
x = 0.088 m → FC= − 108.06 N
Mxx = − RAy x − WB(x − 0.07) = − 108.06x− 3.88(x − 0.07)
x = 0.07m → MB = − 7.29 Nm
x = 0.088 m → MC= − 9.24 Nm
Span CD (0.088 < x < 0.146 m)

RAy WB WC X
0.07m 0.018m
A D
B C
x
X
F yy =−RAy −W B−W C =−104 . 18−3 . 88−4 . 78=−1 12. 84 N
x = 0.088 m → FC = − 112.84 N
x = 0.146 m → FD= − 112.84 N
Mxx = − RAy x − WB(x − 0.07)− WC (x − 0.088)
= − 108.06x− 3.88(x− 0.07) − 4.78(x− 0.146)
x = 0.088 m → MC = − 9.24 Nm
x = 0.146 m → MD= − 15.78 Nm
Span FE (0.02m < x < 0.04 m)
WF
X 0.02m
E G
x F
X

F yy =W F=5 .33 N
x = 0.02 m → FF = 5.33 N
x = 0.04 m → FE= 5.33 N
 107

Mxx = − WF(x− 0.02) =− 5.33(x− 0.02)

x = 0.02 m → MF = 0 Nm
x = 0.04 m → ME= − 0.11 Nm
Span ED (0.04m < x < 0.058 m)

REy
X WF

E 0.02m 0.02m
D
G
F
x
X
F yy =W F +REy =5 .33+865. 56=870 . 88 N
x = 0.04 m → FE = 870.88 N
x = 0.058 m → FD= 870.88 N
M xx =−W F ( x−0.02)−R Ey ( x−0.04 )=−5.33( x−0.02 )−865 .56 ( x−0.04 )
x = 0.04 m → ME = − 0.11 Nm
x = 0.058 m → MD= − 15.78 Nm
Resultant moment,

M rD =√ M 2Dh +M 2Dv =√ 18 .38 2 +15 .78 2 = 24.23 Nm

Therefore maximum bending moment is 24.23 Nm.
Maximum bending moment occurs at gear with key way.

So,
S s=0. 75×0. 3×290=65 . 25 MPa

S s=0. 75×0. 18×414=55 . 89 MPa

Choose, Ss = 55.89 MPa
For rotating shaft with load gradually applied.
Kb = 1.5, Kt = 1, L =204 m
Radius of gyration can be calculated by using Equation 3.90.
d
k=
4
Column action factor can be calculated by using Equation 3.88.
1 1
α= =
1−0 . 0044 ( Lk ) 1−0 . 0044 ( 0. 204×4
d )
 108

d
= d−0 . 0036
Solid shaft having axial loading can be calculated by using Equation 3.86.

√( ) +( K M )
2
16 αF a d
d 3= K b M b+ t t
2
πSs 8

√( )
2
d
×1147.26×d
16 d−0.0036 2
d 3= 6
1 .5×24.23+ + ( 1×114 .86 )
π×55.89×10 8
d = 0.02215 m
d = 22.15 mm
Standard size of shaft is 23 mm
So diameter of the main shaft at 1st position is 23 mm.
The diameter of main shaft is based on 1st position which has maximum
torque. Therefore the optimum diameter is 23 mm to satisfy the various speeds.

4.2.3. Design Calculation of Input Shaft

Design power = 19.4 kW
Shaft speed = 6500 rpm
DD = 46 mm
WB = 2.04 kg = 20 N
Torsional moment of shaft (Mt) can be calculated by using Equation 3.8.
9550×kW 9550×19. 4
M t= = =28. 50
rpm 6500 Nm
For gear (4),
Tangential force can be calculated by using Equation 3.9.
2M t 2×28 . 50
F tD= = =1239 .267
DD 0 . 046 N
Radial force can be calculated by using Equation 3.11.
F rD =F tD tan φ=1239. 27×tan20=451. 06 N
Axial force can be calculated by using Equation 3.10.
F aD =F tD tanψ=1239 . 27×tan23=526 . 04 N
From Horizontal Load Diagram (H.L.D) (From Figure 4.3),
 109

Taking moment about B, ∑ M B += 0 (clockwise positive)

(REx ¿ 0.055)− (FaD ¿ 0.025) = 0
0.055Rex − (526.04 ¿ 0.025) = 0
REx = 239.11 N

∑ F y +↑=0
RCx +R Ex−F aD=0
RCx =526. 04−239 . 11=286 . 93 N
From Vertical Load Diagram (V.L.D) (From Figure 4.3),

Taking moment about C, ∑ M C += 0 (clockwise positive)

( F rD ×0 . 025 ) −( REy ×0 . 055)−( W B×0 . 1 )=0
( 451 . 06×0 .025 )−0 . 055REy −( 20×0 .1 ) =0
REy =168 . 66 N

∑ F y +↑=0
−W B +RCy −F rD +R Ey =0
RCy =20+451 . 06−168 . 66=302. 39 N
Calculation of horizontal shearing force and bending moment.
Span CD (0.12m < x < 0.145 m)

x X
C D
B
RCx
0.12m
X
Fxx = RCx =286.93 N
x = 0.12 m → FC = 286.93 N
x = 0.145 m → FD= 286.93 N
Mxx = RCx (x− 0.12) =286.93(x− 0.12)
x = 0.12 m → MC = 0 Nm
x = 0.145 m → MD= 7.17 Nm
Span ED (0 < x <0.03)
X
 110

D E

x
X

REx
Fxx =− REx = − 239.11 N
x = 0 m → FE = − 239.11 N
x = 0.03 m → FD= − 239.11 N
Mxx = REx¿ x = 239.11x
x = 0 m → ME = 0 Nm
x = 0.03 m → MD= 7.17 Nm
B D
C E
A

0.02m 0.1m 0.025m 0.03m

FaD
H.L.D
RCx 286.93N REx

H.S.F.D
239.11N

7.17Nm

H.B.L.D

WB FrD
V.L.D
RCy REy
282.39N

V.S.F.D
20N 168.66N
5.06Nm
V.B.L.D
2Nm
8.78Nm

C.B.L.D
 111

Figure 4.3. Loading and Bending Moment Diagram of Input Shaft at First Speed
Position
Bending moment and loading diagram of input shaft (first position) are as
shown in Figure. 4.3.
Calculation of vertical shearing force and bending moment.
Span BC (0.02 < x < 0.12m)
 112

WB X
0.02m
A
B x C

Fyy =− WC = − 20 N
x = 0.02 m → FB = − 20 N
x = 0.12 m → FC= − 20 N
Myy = − WC¿ (x− 0.02) = − 20(x− 0.02)
x = 0.02 m → MB = 0 Nm
x = 0.12 m → MC= − 2 Nm
Span CD (0.12m < x <0.145m)

WB X
0.02m 0.1m
A C D
B RCy
x

F yy =−W B +R Cy =−20+302 . 39=282 .39 N

x = 0.12 m → FC = 282.39 N
x = 0.145 m → FD= 282.39 N
M yy =−W B×( x−0. 02 )+R Cy ( x−0 .12 )=−20 (x−0.02 )+302.39( x−0 . 12)
x = 0.12 m → MA = − 2 Nm
x = 0.145 m → MB= 5.06 Nm
Span ED (0 < x <0.03)
X
E
D
x
X

REy
F yy =R Ey =−168 .66 N
 113

x = 0 m → FE = − 168.66 N
x = 0.03 m → FD= − 168.66 N
M yy =RCy ×x=168 . 66 x
x = 0 m → ME = 0 Nm
x = 0.03 m → MD= 5.06 Nm
Span DC (0.03 < x <0.055)
FrD
X 0.03m
E
C
x D REy
X

F yy =−REy +F rD =−168 . 66+451 . 06=282. 39 N

x = 0.03 m → FD = 282.39 N
x = 0.055 m → FC= 282.39 N
M yy =REy ×x−F rD ( x−0.03 )=168 . 66x−451 . 06( x−0. 03)
x = 0.03 m → MD = 5.06 Nm
x = 0.055 m → MB= − 2 Nm
Resultant moment,

M rD =√ M 2Dh +M 2Dv =√(7 . 17 )2 +(5 . 06 )2=8. 78 Nm

Therefore maximum bending moment is 8.78 Nm.
Maximum bending moment occurs at gear with key way.

So,
S s=0. 75×0. 3×290=65 . 25 MPa
S s=0. 75×0. 18×414=55 . 89 MPa
Choose, Ss = 55.89 MPa
For rotating shaft with load gradually applied.
Kb = 1.5, Kt = 1, L =175 m
Radius of gyration can be calculated by using Equation 3.90.
d
k=
4
Column action factor can be calculated by using Equation 3.88.
1 1 d
α= = =
1−0 . 0044 ( Lk ) 1−0 . 0044 ( 0. 175×4
d ) d−0 . 00308

Solid shaft having axial loading can be calculated by using Equation 3.86.
 114

√( ) +( K M )
2
16
3 αF a d 2
d = K b M b+ t t
πSs 8

√( )
2
d
×526.04×d
16 d−0.00308 2
d 3= 1 .5×8.78+ +( 1×28.50 )
π×55.89×106 8
d = 0.0142 m
d = 14.2 mm
Standard size of shaft is 15 mm
Therefore diameter of input shaft is 15 mm.

4.2.4. Design Calculation of Idler Shaft

Design power = 19.4 kW
Shaft speed = 3636.36 rpm
DB = 44 mm
Shaft material is AISI 5160 OQT 700
Torsional moment of shaft (Mt) can be calculated by using Equation 3.8.
9550×kW 9550×19. 4
M t= = =50 . 95
rpm 3636 .36 Nm
Tangential force can be calculated by using Equation 3.9.
2Mt 2×50. 95
F tB= = =2315 . 87
DB 0 .044 N
Radial force can be calculated by using Equation 3.11.
F rB=F tB tan φ=2315 .87×tan20=842 .91 N
Axial force can be calculated by using Equation 3.10.
F aB=F tB tanψ=2315 . 87×tan23=983.03 N
Calculation of horizontal shearing force and bending moment.
Span AB (0 m < x <0.052 m)

X FaB

A x B
X
 115

F xx=−F aB =−983.03 N
x = 0 m → FA = − 983.03 N
x = 0.052 m → FB= − 983.03 N
M xx =−F aB×x
x = 0 m → MA = 0 Nm
x = 0.052 m → MB= − 51.12 Nm
Calculation of vertical shearing force and bending moment.
Span AB (0 m < x <0.052 m)
X FrB

A B
x
X

F yy =−F rB
x = 0 m → FA = − 842.91 N
x = 0.052 m → FB= − 842.91 N
M xx =−F rB×x
x = 0 m → MA = 0 Nm
x = 0.052 m → MB= − 43.83 Nm
Resultant moment,

Mr = √ M 2Bh+ M 2Bv=√(−51 .12 )2+(−43 . 83 )2

= 67.34 Nm
Therefore maximum bending moment is 67.34 Nm.
Maximum bending moment occurs at gear without key way.

So,
S s=0. 3×1630=489 MPa

S s=0. 18×1810=325 . 8 MPa

Choose, Sall = 325.8 MPa
For rotating shaft with load gradually applied.
Kb = 1.5, Kt = 1
L =52 m, D = 44 mm
Radius of gyration can be calculated by using Equation 3.90.
 116

d
k=
4
Column action factor can be calculated by using Equation 3.88.
1 1 d
α= = =
1−0 . 0044
A
( Lk ) 1−0 . 0044 ( 0. 052×4
d ) d−0 . 0009152
B

Fa
H.F.D
RAx
983.03 N
H.S.F.D

H.B.M.D
51.12 Nm

Fr
V.L.D
RAy
842.91 N
V.S.F.D
V.B.M.D
43.83 Nm

C.B.M.D

67.34 Nm

Figure 4.4. Loading and Bending Moment Diagram of Idler Shaft

Bending moment and loading diagram of main shaft (first position) are as
shown in Figure. 4.4.
Solid shaft having axial loading can be calculated by using Equation 3.86.

√( ) +( K M )
2
3 16 αF a d 2
d = K b M b+ t t
πSs 8
 117

√( )
2
d
×983.03×d
16 d−0.0009152 2
d 3= 2×67.34+ +( 1.5×50.95 )
π×325.8×106 8
d = 0.0135 m
d = 13.5 mm
Standard size of shaft is 14 mm
Therefore diameter of Idler shaft is 14 mm.

4.2.5. Sample Calculation for Critical Speed of Input Shaft

The critical speed of the rotation shaft is the speed at which the shaft starts to
vibrate violently in the transverse direction. It is very dangerous to continue to run the
shaft at its critical speed. So, in the designing of the shafts for gearbox, the critical
speed of the shafts is determined. In calculating of the critical speed, the material of
the shaft and the deflection of the shaft are required to determine.
There are two masses on the clutch shaft or input shaft and the deflections of
the clutch shaft are calculated as follows equations. The deflection diagram of the
input shaft is shown in Figure. 4.5.
In calculation of critical speed of shaft, the shaft weight is negligible.
Diameter of the input shaft is 13 mm. Rayleigh-Ritz equation can be used to
determine the critical speed of the system
D = 15 mm
−

ZEI = ∑ A x
1
×0 .1×2. 00=0 .10 m 2
A1 = 2
2
A2 = 0 . 025×2 . 00=0. 05 m
1
×0 .025×(10 . 55−2 . 00)=0 .11 m 2
A3 = 2
1
×0 .03×10 .55=0 .16 m 2
A4 = 2

ZE
I= A1 X 1 + A2 X 2 + A 3 X 3 + A 4 X 4 0
2
X 1 = ×0 .1=0 . 07 m
3
 118

0. 025
X 2=0 . 1+ =0 . 11 m
2
2
X 3 =0 . 1+( ×0 . 025)=0 .12 m
3
1
X 4 =0 .1+0. 025+( ×0. 03 )=0 . 14 m
3
where,
E = 207×109 N/m2
Moment of inertia,
πD4 π (0. 015 )4
I= =
64 64 = 1.40×10-9 m4 =2.49×10-9 m4
Z1 EI=(0 .10×0 . 07)+(0 .05×0 . 11)+(0 .04×0. 12)+(0 .16×0 .14 )
Z1= 7.54× 10-5
i i i
Z 3 EI=A 2 X̄ 2 + A3 X̄ 3 + A 4 X̄ 4

X̄ i2 = 0.025/2 =0.0125

X̄ i3 = 2/3×0.025 =0.02

X̄ i4 =0.025 + 1/3 × 0.03 = 0.04

Z 3 EI=(0 . 05×0 .0125 )+(0 .11×0 .02)+(0.16×0 . 04 )

Z3= 1.55 × 10-5
Z5 EI = A X̄ ii4
4

X̄ ii4 = 1/3× 0.03 =0.01

Z5 EI = (0.16 × 0.01)
Z5 = 3.05× 10-6
Z2 0 . 155
= =2 .82
Z3 0 . 055

Z 2=1 .55×10−5 ×2 . 82=4 .36×10-5

Z4 0 .03
= =0 .55
Z3 0 .055

Z 4 =1. 49×10−5 = 8.43 × 10-6

δ 1=Z 1 −Z 2 =7 .51×10−5 −4 .36×10−5 =3 .16×10−5

δ 2 =Z 4 −Z 5 =8 . 43×10−6 −3. 05×10−6 =5 . 38×10−6

 119

W1= 2.04 × 9.81 = 20 N

W2 = 2.10 N

W1δ 1 =20 ×3.16×10-5 = 6.31×10-4

W2δ 2 = 2.10 ×5.38×10-6 = 1.13×10-5

2
W 1 δ21 =20× ( 3 .16×10−5 ) =1. 99×10−8
W 2 δ 22 =2 .10×(5 . 38×10−6 )2 =6 . 07×10−11
To find the critical speed,

∑ Wδ=6.31×10 -4 +1.13×10−5=6.42×10−4
∑ Wδ2=1.99×10−8+6.07×10−11=1.99×10−8
By using Rayleigh-Ritz equation,
Critical speed of input shaft can be calculated by Equation 3.92.

√
i
g ∑ W nδn
n=1
i
∑ W n δ2n
n=1
ωc =

=
√
9 . 81×6 . 42×10−4
1. 99×10−8

ωc = 561.73 rad/sec
= 33703.94 rpm
The critical speed of Input shaft is 33703.94 rpm.

10 cm 2.5 cm 3cm

W2
W1

A3
A1 A2 A4 Bending
X1 Moment
X3
X4

δ1
Deflection
Z4 δ2 Curve
Z3 Z5
Z
 120

Figure 4.5. Deflection Diagram of Input Shaft

4.3. Design Selection of Bearings
In bearing selection, firstly, choose bearing life of machine 4000 working
hours from Appendix A, Table A.5.
For left bearing selection on the counter shaft
Radial load

Fr = √ R2Ax +R2Ay= √(571.47)2+(287.01)2=639.50 N

Fa = 1123.46 N
n = 5000 rpm
60×n×Lh 60×5000×4000
6
= =1200
L = 10 10 6

Fa
=0 .5
Assume, C0r e =0.44 (From Appendix A, Table A.6)
Fa 1123. 46
=1. 76
VFr = 1×639 .50 , V = 1 (inner ring rotation)
 121

Fa
VFr > e

X = 0.56, Y = 1 (From Appendix A, Table A.6)

P = XVFr + YFa
P = 0.56¿ 1¿ 639.50+1¿ 1123.46
= 1481.58 N

( )
p
Cr
L = P

(1481 .58 )
3
C r

1200 =
Cr = 15.74 kN
Read from Appendix A, Table A.8, select the bearing number 6403 single row deep
groove ball bearing.
Cr = 20.7 kN
C0r = 9.85 kN
Fa 1123. 46
=0 . 11
C0r = 9850 e = 0.3 (From Appendix A,Table
A.6)
Fa
VFr > e

X = 0.56, Y = 1.45 (From Appendix A, Table A.6)

P = XVFr + YFa
P = 0.56¿ 1¿ 639.50+1.45¿ 1123.46
= 1987.14 N

( )
p
Cr
L = P

(1987 . 14 )
3
C r

1200 =
Cr = 21.12kN
Read from Appendix A, Table A.8, select the bearing number 6404 single row deep
groove ball bearing.
Inner diameter of bearing at point A = 20 mm
 122

Outer diameter of bearing at point A =72 mm

Face width of bearing at point A = 19 mm
For right bearing selection on the counter shaft,
Radial load

Fr = √ R 2
Fx +R 2
Fy = √ (1076.27)2
+(807.15)2
=1345.31 N
Fa = 1123.46 N
n = 5000 rpm
60×n×Lh 60×5000×4000
6
= =1200
L = 10 10 6

Fa
=0 .5
Assume, C0r e =0.44 (From Appendix A, Table A.6)
Fa 1123. 46
=0 . 84
VFr = 1×1 345. 31 , V = 1 (inner ring rotation)
Fa
VFr > e

X = 0.56, Y = 1 (From Appendix A, Table A.6)

P = XVFr + YFa
P = 0.56¿ 1¿ 1345.31+1¿ 1123.46
= 1876.84 N

( )
p
Cr
L = P

(1876 . 84 )
3
C r

1200 =
Cr = 19.94 kN
Read from Appendix A, Table A.8, select the bearing number 6403 single row deep
groove ball bearing.
Cr = 20.7 kN
C0r = 9.85 kN
Fa 1123. 46
=0 . 11
C0 = 9850 e = 0.3 (From Appendix A, Table
A.6)
 123

Fa
VFr > e

X = 0.56, Y = 1.45 (From Appendix A, Table A.6)

P = XVFr + YFa
P = 0.56¿ 1¿ 1345.31+1.45¿ 1123.46
= 2382.40 N

( )
p
Cr
L = P

(2382 . 40 )
3
C r

1200 =
Cr = 25.32 kN
Read from Appendix A, Table A.8, select the bearing number 6404 single row deep
groove ball bearing.
Inner diameter of bearing at point A = 20 mm
Outer diameter of bearing at point A =72 mm
Face width of bearing at point A = 19 mm
For left bearing selection on the main shaft,
Radial load

Fr = √ R2ax +R 2ay =√(125.92)2+(104.18)2=163.43 N

Fa = 1147.26 N
n = 1612.90 rpm
60×n×Lh 60×1612 . 90×4000
6
= =387 . 10
L = 10 10 6
Fa
=0 .5
Assume, C0r e =0.44 (From Appendix A, Table A.6)
Fa 1147. 26
=7 . 02
VFr = 1×163 . 43 , V = 1 (inner ring rotation)
Fa
VFr > e

X = 0.56, Y = 1 (From Appendix A, Table A.6)

P = XVFr + YFa
P = 0.56¿ 1¿ 163.43+1¿ 1147.26
= 1238.77 N
 124

( )
p
Cr
L = P

( )
3
Cr
387.10 = 1238 . 77
Cr = 9.03 kN
Read from Appendix A, Table A.8, select the bearing number 6004 single row deep
groove ball bearing.
Cr = 9.4 kN, C0r = 5.05 kN
Fa 1147. 26
=0 . 23
C0r = 5050 e = 0.34 (From Appendix A, Table
A.6)
Fa
VFr > e

X = 0.56, Y = 1.31 (From Appendix A, Table A.6)

P = XVFr + YFa
P = 0.56¿ 1¿ 163.43+1.31¿ 1147.26
= 1594.42 N

( )
p
Cr
L = P

( )
3
Cr
387.10 = 1594 . 42
Cr = 11.62 kN
Read from Appendix A, Table A.8, select the bearing number 6204 single row deep
groove ball bearing.
Inner diameter of bearing at point A = 20 mm
Outer diameter of bearing at point A =47 mm
Face width of bearing at point A = 14 mm
For left bearing selection on the main shaft,
Radial load

Fr = √ R 2
ax +R 2
ay = √ (1021.34 )2
+(865.55 )2
=1338.77 N
Fa = 1147.26 N
n = 1612.90 rpm
 125

60×n×Lh 60×1612 . 90×4000

6
= =387 . 10
L = 10 10 6

Fa
=0 .5
Assume, C0r e =0.44 (From Appendix A, Table A.6)
Fa 1147. 26
=0 .86
VFr = 1×1338 .77 , V = 1 (inner ring rotation)
Fa
VFr > e

X = 0.56, Y = 1 (From Appendix A, Table A.6)

P = XVFr + YFa
P = 0.56¿ 1¿ 1338.77+1¿ 1147.26
= 1896.97 N

( )
p
Cr
L = P

( )
3
Cr
387.10 = 1896 . 97
Cr = 13.83 kN
Read from Appendix A, Table A.8, select the bearing number 6304 single row deep
groove ball bearing.
Cr = 15.9 kN
C0r = 7.85 kN
Fa 1147. 26
=0 .15
C0r = 7850 e = 0.34 (From Appendix A, Table
A.6)
Fa
VFr > e

X = 0.56, Y = 1.31 (From Appendix A, Table A.6)

P = XVFr + YFa
P = 0.56¿ 1¿ 1338.77+1.31¿ 1147.26
= 2253.62 N

( )
p
Cr
L = P
 126

( )
3
Cr
387.10 = 2252 . 62
Cr = 16.42 kN
Read from Appendix A, Table A.8, select the bearing number 6403 single row deep
groove ball bearing.
Inner diameter of bearing at point A = 20 mm
Outer diameter of bearing at point A =72 mm
Face width of bearing at point A = 19 mm

4.4. Main Specification of Hijet

Using the following design data, the capacity of the propeller shaft can be
calculated. Specifications of propeller shaft for Hijet is illustrated in Table 4.1.
Design data:
Table 4.1. Specifications of Propeller Shaft for Hijet

Power 20 kW

1st Speed, N 1543.75 rpm

Propeller Shaft Length, Lp 325 mm

Diameter Ratio, K 0.9

Commercial Steel Shafting, Ss (allowable) 55MPa

4.4.1. Design Calculation of Propeller Shaft

Using the following design data, suitable diameter can be calculated.
Design data:
Power = 19.4 kW
Speed = 1543.75 rpm (1st speed)
Propeller Shaft length: Lp = 325 mm
Diameter ratio: Kr = 0.9
2
Commercial steel shafting, Ss = 55 MN/m
For rotating shaft,
Kb = 1.5, Kt = 1.0
The torsional moment action on the shaft can be calculated by using Equation 3.8.
 127

Power (kW )×9550

Mt = N
19 . 4×9550
= 1543 .75
= 123.73 Nm
The rectangular moment of inertia,
π 4 4
(d 0 −d i )
I = 64
For cross section area of shaft,
π 2 2
(d 0 −d i )
A =4
Radius of gyration can be calculated by using Equation 3.90.

√
π
( d 4 −d 4i )
64 0

k = √ I π 2 2
( d −d )
A= 4 0 i

=
1
4
×
√
( d 20−d 2i )( d 20 +d 2i )
( d 20 −d 2i )

=
1
4
×d 0 ×
d 20 d 2i
d 2
0
+ 2
d0 √
1
×d 0 ×√ 1+ K 2r
=4
1
×d 0 ×√ 1+ 0. 9 2
=4 = 0.34d0
Column action factor of the shaft can be calculated by using Equation 3.88.
1

α =
1−0 . 0044 ( ) Lp
k
1

=
1−0 . 0044
( 0 . 325
0 . 34d0 )
d0
−3
= d 0 −4 . 25×10
Axial force can be calculated by using Equation 3.95.
 128

2×μ×M t
Fa = PD
2×0 . 05×123 . 73

=
( 2 )
d 0 +d i d 0
×
d0

4×0 . 05×123 . 73
= (1+ K r )×d 0
13 . 02
= d0
The diameter of hollow shaft can be calculated by using Equation 3.87.

√( )
2
16 α×F a ×d 0
K b M b+ (1+ K 2r ) +( K t M t )2
d 30 4
= π ×S s (1−K r )
8

√ (( ) )
2
13.02d 20
16 d 20 −4.25×10−3 d 0
6 4
( 1+0.92 ) +( 1×123.73 )2
= π×55×10 (1−0.9 )
8
d0 = 0.0322 m
Standard size of shafting, d0 = 0.033 m = 33 mm
di = 0.029 m = 29 mm

4.4.2. Critical Rotation Speed

By using the following design data, calculation of critical rotation speed can
be determined.
Data design;
The outside diameter of shaft : d0 = 33 mm = 0.033 m
The inside diameter of shaft : di = 29 mm = 0.029 m
The length of propeller shaft : Lp = 325 mm = 0.325 m
Acceleration due to gravity : g = 9.81 m/sec2
Modulus of elasticity for steel : E = 1.96¿ 1011N/m2
Density of steel : ρ = 7860 kg/m3
= 77106.6 N/m3
 129

The critical rotation speed can be calculated by using Equation 3.96,

√
2
60 π EI
2π L2p ρA
Nc = , rpm
π 4 4
( d 0 −d i ) 4
I = 64 ,m
π 2 2
( d0−d i ) 2
A =4 ,m
For propeller shaft,

60
×
π2
Nc = 2π 0 .325
2
×
√
1. 96×1011 (0 . 033 4 −0 .029 4 )
77106 .6×16×(0 . 0332 −0 . 0292 )
= 15624.47 rpm
These equation apply for smooth tubes, propeller shaft only achieve 80-90%
of this speed because of play in bearings and sliding pieces and additional dimensions
[05Saw].
In actual,
For propeller shaft,
Nc = 0.9 ¿ 15624.47
= 14062.02 rpm
Propeller shafts are so designed that the calculated critical speed is about 60
per cent higher than the engine speed at maximum power.
For propeller shaft,
Nope = 0.6¿ 14062.02
= 8437.21 rpm

4.4.3. Design Calculation of Torque for the Shaft

Design data:
Outside diameter of shaft : d0 = 0.033 m

Inside diameter of shaft : di = 0.029 m

The safe shear stress : Ss = 55 MN/m2
For polar moment of inertia of the shaft,
π 4 4
( d 0−d i )
Jp = 32
 130

π
= ( 0. 033 4 −0 . 0294 )
32 = 4.70¿ 10 −
8
m4
For the distance from the neutral axis to the outermost fiber of the shaft,
d0
y = 2
0 . 033
=
2
= 0.02 m
Design torque for the shaft can be calculated by Equation 3.98;
Td Ss
Jp = y

J p Ss
T d=
y
4 .70×10-8×55×106
=
0 . 02 = 156.63 Nm

4.4.4. Calculation of Actual Maximum Output of Engine

In maximum output of engine = 19.4 kW at 6500 rpm
Torque of engine,
9550×kW
T = rpm
9550×19 . 4
=
6 500
= 28.50 Nm
Gear ratios of hijet are as follows:
Position Gear Ratio
First gear 4.0
Second gear 2.3
Third gear 1.5
Fourth gear 1.0
Reverse gear 2.6
Final drive ratio 6.29
η =95 % [Ste]
Transmission efficiency, T
 131

In maximum actual output power, Power = 19.4¿ 0.95 = 18.43 kW

Speed, RPM = 6500¿ 0.95= 6175 rpm
In maximum actual output power is 19.4 kW at 6175 rpm.
4.4.5. Calculation of Propeller Shaft Turning Speed
To determine the turning speed of a propeller, the engine speed and gear
reduction must be known.
Speed (RPM )
Propeller shaft turning speed=
Gear Reduction
For first gear position,
6175
N1 = 4 . 0
= 1543.75 rpm
For second gear position,
6175
N2 = 2 .3
= 2684.78 rpm
For third gear position,
6175
N3 = 1 .5
= 4116.67rpm
For fourth gear position,
6175
N4 = 1
= 6175 rpm
For reverse gear position,
6175
NR = 2 .6
= 2375 rpm

4.4.6. Calculation of Torque Transmitted by the Propeller Shaft

Transmitted torque by the propeller shaft is obtained by using Equation 3.97,
T t =T e G

Overall gear ratio, G=gear reduction ratio × final drive ratio

For first gear position,
 132

Overall Gear Ratio; G = 6.29 × 4.0 = 25.14

18 . 43
=4 . 61 kW
Power, P1 = 4 . 0
Speed, N1 = 1543.75 rpm
9 550×P1
Te = N1

9550×4 . 61
=
1543 . 75
= 28.50 Nm
T t =T e G
= 28.50 × 25.14
= 716.65 Nm
For second gear position,
Overall Gear Ratio; G = 6.29 × 2.3 = 14.46
18 .43
=8.01
Power, P2 = 2.3 kW
Speed, N2 = 2684.78 rpm
9 550×P2
Te = N2

9550×8 . 01
=
2684 .78
= 28.50 Nm
T t =T e G
= 28.50 × 14.46
= 412.07 Nm
For third gear position;
Overall Gear Ratio; G = 6.29 × 1.5 = 9.43
18 . 43
=12. 29
Power, P3 = 1 .5 kW
Speed, N3 = 4116.67 rpm
9 550×P3
Te = N3
 133

9550×12. 29
=4116 . 67
= 28.50 Nm
T t =T e G
= 28.50 × 9.43
= 268.74 Nm
For fourth gear position,
Overall Gear Ratio; G = 6.29 × 1 = 6.29
18 . 43
=18. 43
Power, P4 = 1 kW
Speed, N4 = 6175 rpm
9 550×P 4
Te = N4

9550×18 . 43
=6175
= 28.50 Nm
T t =T e G
= 28.50 × 6.29

= 179.16 Nm
For reverse gear position,
Overall Gear Ratio; G = 6.29 × 2.6 = 16.34
18 . 43
Power, PR = 2.6
= 7.09 kW
Speed, NR = 2375 rpm
9 550×P R
Te = NR

9550×7 . 09
=2375
= 28.50 Nm
T t =T e G
 134

= 28.50× 16.34
= 465.82 Nm

4.4.7. Torque of Propeller Shaft

Engine actual maximum output is 18.43 kW at 6175 rpm
N ×T
P = 9550
9550×P 9550×18 . 43
=
T = N 6175 = 28.50 Nm

4.5. Design Calculation of Differential Gear

All cars have a differential. A differential is a device, usually consisting of
gears, for allowing each of the driving wheels to rotate at different speeds, while
supplying equal torque to each of them. Specifications of differential gear for Hijet is
shown in Table 4.2.
Table 4.2. Specifications of Differential Gear for Hijet
Final drive 6.29
Pitch circle diameter, d02 165 mm
Shaft angle, Σ 90
Material AISI 5160 OQT 400
Number of teeth of gear, ng 44
Number of teeth of pinion, np 7

4.5.1. Design Calculation of Spiral Bevel Gear and Pinion

(1) Generation cone angle of pinion, p1 can be calculated by Equation 3.24,

( )
np
ng
tanδp1 =

( )
np
tan =9. 04
ng
δp1 =
p2 = Σ – p1
= 90 – 9.04= 80.96
(2) Cone distance, RA can be calculated by Equation 3.29,
 135

d 02 165
= =83 .54
RA =2sinδ p2 2×sin80 . 96 mm
(3) Tooth face width, b can be calculated by Equation 3.32,
R A 83. 54
=
b = 3. 5 3 . 5 = 23.87 mm
use b = 24 mm
(4) Normal module, mn can be calculated by Equation 3.37,
b 24
= = 2.5 mm
mn = 9 9
(5) Normal pitch circle radius, P can be calculated by Equation 3.38,
mn ×n g
Pn = 2×sinδ p2
2. 5×44
=55 .69
= 2×sin80 .96 mm
(6) Inner cone distance, Ri can be calculated by Equation 3.39,
R i = RA – b
= 83.54 – 24 = 59.54 mm
(7) Pitch circle diameter of pinion, d01 can be calculated by Equation 3.40,
d 02
ms = ng
165
= 44 = 3.75
d01 = np ¿ ms = 7 ¿ 3.75
= 26.25 mm
(8) Intermediate value, 1+ x1 can be calculated from Table A.1 of Appendix A.
1 + x1 = 1.438 (From Appendix Table A.7)
(9) Addendum of pinion, hk1 can be calculated from Equation 3.43.
hk1 = (1 + x1) mn
= 1.438 ¿ 2.5 = 3.60 mm
(10) Addendum of crown wheel, hk2 can be calculated from Equation 3.44.
hk2 = 2mn− hk1 = (2¿ 2.5) − 3.60
=1.41 mm
 136

Table 4.3. Results for Spiral Bevel Gear and Pinion

Description Nomenclature Result Unit

Cone distance RA 83.12 mm

Tooth width b 24 mm
Normal module mn 2.5 mm
Normal pitch circle radius P 55.69 mm
Inner cone distance Ri 59.12 mm

Results for spiral bevel gear and pinion is illustrated in Table 4.3.
4.5.2. Calculation of Gear Blank Dimensions
Dimensions of gear blank can be calculated by the following Equation 3.45 to
Equation 3.58. Gear blank dimension for shaft at right angle is shown in Figure 4.6.

(1) a 1= b cos δp1 = 24 ¿ cos  = 23.70 mm

(2) k 1 = hk1 cos δ p1 = 3.60¿ cos  = 3.55 mm

(3) c 2 = h k2 cos δ p1 = 1.41 ¿ cos  = 1.39 mm

(4) a 2 = b sin δ p1 = 24 ¿ sin  = 3.7707 mm

(5) k 2 = hk2 sin δ p1 = 1.41¿ sin  = 0.22 mm

(6) c 1 = h k1 sin δ p1 = 3.60 ¿ sin  = 0.57 mm

(7)
d ka1 = d o1 + 2 k 1 = 26.25 + (2 ¿ 3.55) = 33.55 mm

(8)
d ki1 = d ka1 − 2 a2 = 33.55 − (2 ¿ 3.77) = 25.81 mm

(9)
d ka2 = d o2 + 2 k 2 = 165 + (2 ¿ 0.22) = 165.44 mm

(10)
d ki2 = d ka2 − 2 a1 = 165.44 – (2 ¿ 23.70) = 118.04 mm
d o2 165
W1 = − ( c 1+ a 1)
(11) 2 = 2 – (0.57 + 23.70) = 58.23 mm
d o1 26 . 25
W2 = − ( c 2 + a2 )
(12) 2 = 2 – (1.39 + 3.77) = 7.97 mm
 137

Figure 4.6. Gear Blank Dimension for Shaft at Right Angle [92Str]

Table 4.4. Results for Gear Blank Dimension

No. Formula Result Unit

1 a1 = b cos P1 23.70 mm
2 k1 = hk1 cos P1 4.26 mm
3 c2 = hk2 cos P1 1.67 mm

4 a2 = b sin P1 3.77 mm

5 k2 = hk2 sin P1 0.27 mm

6 c1 = hk1 sinP1 0.68 mm

7 dka1 = do1 + 2k1 34.77 mm
8 dki1 = dka1 − 2a2 42.31 mm
9 dka2 = do2 + 2k2 165.53 mm
10 dki2 = dka2 − 2a1 118.13 mm
d o2
2 ( 1 1)
11 W1 = − c +a 58.12 mm

d
12 W 2 = o1 − ( c 2 + a2 ) 7.69 mm
2
Results for gear blank dimension is illustrated in Table 4.4.
138
 139

4.5.3. Design Calculation of Straight Bevel Gear

The specifications of the straight bevel gear are as follows:
Transmission ratio = 1.6:1
Modulus of Elasticity, E = 207 GPa
Tensile Strength = 2220 MPa
Brinell hardness = 627
Pinion Speed, Np = 6175 rpm
The number of teeth of pinion, np = 10
The number of teeth of gear, ng = 16
Dimensions of Straight Tooth Bevel Gear
The dimensions of straight tooth bevel gear are calculated by using the formulae.
Transmission ratio, i
n g 16
= =1. 6
i = n p 10
Pitch cone angle of pinion (1) can be calculated by using Equation 3.24.
n p 10
=
tanδp1 =
n g 16
∘
δp1 = 32.01
Pitch cone angle of wheel, 2
n g 16
=
tanδp2 =
n p 10
∘
δp2 = 57.99
Shaft angle, 

Σ δ p1 +δ p2

∘ ∘ ∘
32 .01 +57. 99 =90 
Design procedures are using unknown diameter case.
9550×kW 9550×18. 43
= =28 . 50
Np 6175
Mt = Nm
The formative number of teeth for pinion and gear can be calculated by using
Equation 3.68 and Equation 3.69.
np
×√ n2p + n2g =12
nfp
n
= g
 140

ng
×√ n2p + n2g =30
nfg
n
= p
If nfp = 12, yp =0.079
If nfg = 30, yg =0.118
Actual induced stress can be calculated by using Equation 3.70.

( )
2×M t Lc
×
2 Lc−b
Sind = m by p πn p
Cone length (Lc) can be calculated by using Equation 3.72.
n p ×m
×√ 1+V . R2
Lc = 2
10×m
= × √1+1 .6 2=9 . 43 m
2
Lc
b = 3 = 3.15m

Sind
2
2×28 . 50
× (
9 . 44m
= m ×3 . 15m×0 . 079×π ×10 9 . 43m−3. 15m
)
10 . 96
3
= m
1
V . F=
Let velocity factor, 2
Su
S0 = =740
Endurance stress, 3 MPa

Sall =
S0 ×V . F
1
=740× =370
2 MPa
Sind = Sall
10 . 96
m3 = 370¿ 106
m = 3.09 mm
Take m = 2.5 mm (from Standard module series)
Dp = m¿ np= 3¿ 10 = 30 mm
Dg = m¿ ng= 3¿ 16 = 48 mm
 141

π ×D p ×N p π ×30×10−3 ×6175
= =9 .70
V = 60 60 m/s
For strength check,
Allowable stress can be calculated by using Equation 3.76.

Sall =
S0
( 5.6
5. 6+ √ v )
=740×106 ×
( 5 . 6+5 .6√ V )=475 . 53 MPa
10 . 96
−3 3
=405. 79
Sind = (3×10 ) MPa
Sall > Sind. Design is satisfied.
b = 3.15 ¿ 3 = 9.43 mm
Lc = 9.44¿ 3 = 28.30 mm
For dynamic check,
The limiting endurance load can be calculated by using Equation 3.78.

( )
Lc −b
S0 ×b× y p ×π×m×
Lc
F0 =

=740×106 ×9 . 43×10−3 ×0 . 079×π ×3×10−3 × (2828 .30−9

.30
. 43
)
=3465.1947 N
The limiting wear load can be calculated by using Equation 3.79.
0 .75×D p ×b×K×Q
Fw = cosα p
2×nfg
=1 . 43
Q n +n
= fg fp
Ses = 2.75¿ BHN − 70 = 1654.25 MPa

K
S 2es×sin φ 2
= 1. 4
×
E [ ]
=
(1654 . 25×106 )2 ×sin 20
1. 4
×
2
207×10 9[=6 . 46×10 6
]N/m2
0 .75×30×10−3×9. 43×10−3 ×6 . 46×106 ×1 . 43
Fw = cos32. 02
 142

= 2309.99 N
2×M t
Ft = Dp
2×28 .50
−3
= 30×10 = 1900.21 N
Dynamic load can be calculated by using Equation 3.81.
21×V ×(b×C + F t )
Ft+
Fd = 21×V + √ b×C+ F t

Precision cut error (0.01mm) at m = 2.5 mm

C = 114¿ 103 N/m
21×9 .70×( 9. 43×10-3 ×114×10 3 +1900 .21 )
1900 .21+
Fd = 21×9 .70+ √ 9. 43×10−3 ×114×103 +1900 . 21
= 4247.30 N
Fw < Fd and F0 < Fd.
So, Design is not satisfied.
Try m = 4 mm,
Dp = 40 mm,
V = 12.93 m/s,
Lc = 38 mm,
b = 13 mm,
F0 = 6283.02 N,
Fw = 4244.29 N,
Ft = 1425.16 N,
Fd = 3850.76 N
Fw > Fd and F0 > Fd.
So, Design is satisfied.
Tip circle diameter of pinion, da1
da1 = d1 + 2mcosδ1
∘
=40+(2×4 cos32.01 ) = 46.78 mm
Tip circle diameter of gear, da2
da2 = d2 + 2mcosδ2
∘
=64+(2×4 cos57 . 99 ) = 68.24 mm
 143

Middle circle diameter of pinion, dm1

dm1 = d1 − bsinδ1
∘
=40−(13×sin 32.01 ) =33.12 mm
Middle circle diameter of gear, dm2
dm2 = d2 − bsinδ2
∘
=64+(2×4 cos57 .99 )
= 52.98 mm

Table 4.5. Results Dimensions of Straight Tooth Bevel Gear

Description Nomenclature Dimensions Units
Pinion 1 32.01 degree
Pitch cone angle
Gear 2 57.99 degree
Pinion da1 46.78 mm
Tip circle diameter
Gear da2 68.24 mm
Pinion dm1 33.11 mm
Middle circle diameter
Gear dm2 57.11 mm

Shaft angle  90 degree

Module m 4 mm
Cone distance R 37.73 mm
Face width b 13 mm

Results dimensions of straight tooth bevel gear is shown in Table 4.5.

4.6. Summary
This chapter is expressed the design calculation for gear box. Design
calculation of gear for gear box is used 20 kW design power at 6500 rpm of engine
speed. Firstly, the design calculation of gear mesh have been carried out to get
adequate strength. Strength check and dynamic check are explained to get the design
satisfactory. If the design is not satisfactory, keeping on calculating the increasing
module until it is satisfactory. Secondly, the design of shaft and propeller shaft have
been calculated by using ASME code equation. After calculating the shaft diameter,
bearing selection is carried out to get the bearing size. And then, the torque
transmitted by the propeller shaft for every speed have been evaluated. Finally, the
 144

design of spiral bevel gear and straight bevel gear have been calculated by using
Lewis equation.